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CN101516502B - Catalyst coated diesel particulate filter, method for the production thereof and use thereof - Google Patents

Catalyst coated diesel particulate filter, method for the production thereof and use thereof Download PDF

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Publication number
CN101516502B
CN101516502B CN2007800347195A CN200780034719A CN101516502B CN 101516502 B CN101516502 B CN 101516502B CN 2007800347195 A CN2007800347195 A CN 2007800347195A CN 200780034719 A CN200780034719 A CN 200780034719A CN 101516502 B CN101516502 B CN 101516502B
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China
Prior art keywords
zeolite
catalyst
filter
particulate filter
platinum group
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CN2007800347195A
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CN101516502A (en
Inventor
M·克格尔
M·普法伊菲尔
G·耶斯克
F-W·许策
S·弗朗茨
T·克罗伊策
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Umicore AG and Co KG
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Umicore AG and Co KG
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
    • F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
    • F01N3/033—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters in combination with other devices
    • F01N3/035—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters in combination with other devices with catalytic reactors, e.g. catalysed diesel particulate filters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/38—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals
    • B01J23/40—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals of the platinum group metals
    • B01J23/42—Platinum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34—Chemical or biological purification of waste gases
    • B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
    • B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34—Chemical or biological purification of waste gases
    • B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
    • B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
    • B01D53/944—Simultaneously removing carbon monoxide, hydrocarbons or carbon making use of oxidation catalysts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/38—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals
    • B01J23/40—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals of the platinum group metals
    • B01J23/44—Palladium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J29/00—Catalysts comprising molecular sieves
    • B01J29/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites
    • B01J29/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
    • B01J29/18—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the mordenite type
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J35/00—Catalysts, in general, characterised by their form or physical properties
    • B01J35/19—Catalysts containing parts with different compositions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/02—Impregnation, coating or precipitation
    • B01J37/024—Multiple impregnation or coating
    • B01J37/0244—Coatings comprising several layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/02—Impregnation, coating or precipitation
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    • B01J37/0246—Coatings comprising a zeolite
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/02—Impregnation, coating or precipitation
    • B01J37/024—Multiple impregnation or coating
    • B01J37/0248—Coatings comprising impregnated particles
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
    • F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
    • F01N3/022—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous
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    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
    • F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
    • F01N3/022—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous
    • F01N3/0222—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous the structure being monolithic, e.g. honeycombs
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/0807—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents
    • F01N3/0821—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents combined with particulate filters
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/0807—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents
    • F01N3/0828—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents characterised by the absorbed or adsorbed substances
    • F01N3/0835—Hydrocarbons
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/10—Noble metals or compounds thereof
    • B01D2255/102—Platinum group metals
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01D2255/00—Catalysts
    • B01D2255/20—Metals or compounds thereof
    • B01D2255/206—Rare earth metals
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/20—Metals or compounds thereof
    • B01D2255/207—Transition metals
    • B01D2255/20738—Iron
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01D2255/00—Catalysts
    • B01D2255/20—Metals or compounds thereof
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    • B01D2255/20761—Copper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/50—Zeolites
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/90—Physical characteristics of catalysts
    • B01D2255/912—HC-storage component incorporated in the catalyst
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/90—Physical characteristics of catalysts
    • B01D2255/915—Catalyst supported on particulate filters
    • B01D2255/9155—Wall flow filters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J29/00—Catalysts comprising molecular sieves
    • B01J29/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites
    • B01J29/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
    • B01J29/08—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the faujasite type, e.g. type X or Y
    • B01J29/10—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the faujasite type, e.g. type X or Y containing iron group metals, noble metals or copper
    • B01J29/12—Noble metals
    • B01J29/126—Y-type faujasite
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J29/00—Catalysts comprising molecular sieves
    • B01J29/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites
    • B01J29/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
    • B01J29/70—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of types characterised by their specific structure not provided for in groups B01J29/08 - B01J29/65
    • B01J29/72—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of types characterised by their specific structure not provided for in groups B01J29/08 - B01J29/65 containing iron group metals, noble metals or copper
    • B01J29/74—Noble metals
    • B01J29/7415—Zeolite Beta
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01J29/00—Catalysts comprising molecular sieves
    • B01J29/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites
    • B01J29/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
    • B01J29/80—Mixtures of different zeolites
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2370/00—Selection of materials for exhaust purification
    • F01N2370/02—Selection of materials for exhaust purification used in catalytic reactors
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2370/00—Selection of materials for exhaust purification
    • F01N2370/02—Selection of materials for exhaust purification used in catalytic reactors
    • F01N2370/04—Zeolitic material
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2510/00—Surface coverings
    • F01N2510/06—Surface coverings for exhaust purification, e.g. catalytic reaction
    • F01N2510/063—Surface coverings for exhaust purification, e.g. catalytic reaction zeolites
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
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    • F01N2510/00—Surface coverings
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    • F01N2510/068—Surface coverings for exhaust purification, e.g. catalytic reaction characterised by the distribution of the catalytic coatings
    • F01N2510/0682—Surface coverings for exhaust purification, e.g. catalytic reaction characterised by the distribution of the catalytic coatings having a discontinuous, uneven or partially overlapping coating of catalytic material, e.g. higher amount of material upstream than downstream or vice versa
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
    • Y02A50/00—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE in human health protection, e.g. against extreme weather
    • Y02A50/20—Air quality improvement or preservation, e.g. vehicle emission control or emission reduction by using catalytic converters
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S502/00—Catalyst, solid sorbent, or support therefor: product or process of making
    • Y10S502/514—Process applicable either to preparing or to regenerating or to rehabilitating catalyst or sorbent

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  • Chemical & Material Sciences (AREA)
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  • Combustion & Propulsion (AREA)
  • Organic Chemistry (AREA)
  • Materials Engineering (AREA)
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  • Crystallography & Structural Chemistry (AREA)
  • Catalysts (AREA)
  • Exhaust Gas After Treatment (AREA)
  • Exhaust Gas Treatment By Means Of Catalyst (AREA)

Abstract

A diesel particulate filter having an oxidation catalyst comprising platinum and palladium deposited thereon is described. The conversion of hydrocarbons and carbon monoxide can be significantly improved by incorporating zeolite as the HC storage component into the oxidation catalyst. Further, the particulate filter is further coated with a second catalyst containing no zeolite over a part of the length from the inlet end.

Description

The diesel particulate filter of catalyst-coated, its preparation method and application
Technical field
The present invention relates to be used for the diesel particulate filter of the catalyst-coated of clean diesel engine exhaust, method and its application of filter application.
Background technology
Particulate filter can remove by filter the particle exhaust gas constituents, particularly soot particulates (Ru β partikel) in the engine exhaust gas, therefore can prevent that they are discharged into atmosphere.In principle, can use surface filter or deep filter (Tiefenfilter) to realize this purpose.Surface filter is made up of ceramic masses such as carborundum, cordierite, aluminium titanates or mullite usually.The filtration vessel levels that these filters reached is greater than 95%.For surface filter,, also can use the open architecture that is used for the soot particulates deposition as possibility.These open architectures mainly are ceramic foam or the filter that comprises metal cloth.The filter efficiency of these open filter systems is well below the filter efficiency (＜70%) of common surface filter.
Yet the real challenge of particulate filter work is not the filtration of soot particulates in the engine exhaust gas, but the periodic regeneration of filter device therefor.Because in the passenger cars diesel engines in modern times; The required temperature greater than 550 ℃ of igniting and aerobic burning cigarette ash only could realize under operating at full capacity usually; Therefore other method of absolute demand is filtered the oxidation of soot particulates, to prevent the obstruction of filter.Usually, distinguish with the active heating means passive herein.In the situation of active method, can improve the temperature of particulate filter through burner like electric heater (like glow plug or microwave applicator) or use fuel work.This type active method always can relate to more demand for fuel.Therefore, the passive method of preferred use in many systems that are purchased.In the situation of passive system, use catalyst can reduce the required firing temperature of burning soot particulates.This can realize through two kinds of different thinkings.A kind of thinking is to use organic metal fuel additive such as cerium compound and iron compound as homogeneous catalyst, and it can burn and enter into soot layer with fuel, distributes admirably with the form of metal cluster (cluster).Another kind of thinking for the additive based system is to use the catalyst activity material to come the coated particle filter.
Usually be not enough to guarantee that filter all can regenerate completely because reduce the cigarette ash firing temperature in all working state of engine, therefore in practice at present, adopt combination passive and active method usually through catalysis process.Found that particulate filter is particularly useful with the combination of the oxidation catalyst that is arranged on the upper reaches.Because the injection of additional fuel and the combination of other method relevant with engine (like partial throttling) are arranged, unburned fuel and carbon monoxide arrive diesel oxidation catalyst and are catalytically converted into carbon dioxide and water there.Therefore the hot heat exhaust gases that reaction is discharged also heats the particulate filter in downstream.With catalyst-coated through filter or to reduce the cigarette ash firing temperature through the method for using fuel additive combined, can reduce required injection and almost can be in any operating point of the characteristic pattern of engine with filter regeneration.
Comprise in the exhausted gas post-processing system of particulate filter of catalyst-coated in the first generation, usually filter is arranged on after one or two upstream oxidation catalyst of motor vehicle bottom.Different with it is in the new waste gas after-treatment system, filter to be installed in as close as possible engine downstream place.Because the construction space finite sum will reduce expense, in these situation, can oxidation catalyst partly or wholly be applied to filter.This type of filter near the engine setting must have corresponding high oxidative capacity, to meet in desired travel distance the legal restrictions to carbon monoxide (CO) and hydrocarbon (HC).In addition, it also must will transform at the hydrocarbon that the active filter regeneration period is injected in the whole service time, realizes the desired heat release of cigarette ash firing temperature to produce thus.In addition, be used for this type of catalyst activity coating and must have high heat endurance near the filter of engine.
So far, almost only there is the filter coating that comprises platinum to be used in the diesel-powered bus.The coating that comprises platinum and palladium is known (DE 102004040549A1) too.It should be noted that the coating that comprises platinum and palladium has extraordinary heat endurance, but its fresh activity that has is lower than the catalyst coatings that only comprises platinum.The principle of the coating that comprises platinum and palladium has been described not long ago first.Because the Pt/Pd coating is the significantly lower and decline of relevant catalytic activity with it to the tolerance of sulfur poisoning, hindered the exhaust gas catalytic converter that palladium is used for diesel-powered bus since for a long time.Yet because sulfurization is at high temperature reversible poisoning, therefore in the situation of periodically active regeneration system such as diesel particulate filter, the noble metal site of catalyst coatings is in regeneration period desulfurization side by side.Can recover initial oxidation activity again like this.
Especially, WO 02/26379A1 has described and has comprised the soot filter of two catalyst layers up and down.Ground floor is positioned at the intake channel of filter and comprises the component that is used for oxidizing carbon monoxide and hydrocarbon.These components are made up of the carrier mass that deposits the platinum group metal on it, and said carrier mass is selected from aluminium oxide, silica, titanium oxide, zirconia and zeolite, and the platinum group metal is selected from platinum, palladium and rhodium.The second layer is applied to ground floor, and comprises the component that is used to reduce the cigarette ash firing temperature, more specifically is at least a oxygen storage compounds and at least a platinum group metal.
Summary of the invention
The purpose of this invention is to provide the diesel particulate filter of the catalyst-coated that carbon monoxide with improvement and hydrocarbon transform, in addition, even under the regular situation that repeats to regenerate of filter, said filter still has high ageing stability.
The specific embodiment
Particulate filter through according to the catalyst-coated of main claim is realized said purpose.The preferred embodiment of filter, the method that is used for filter application and its application have been detailed in the dependent claims.
Particulate filter has entrance side and outlet side and the shaft length that is used for waste gas.Filter is coated with first catalyst in its whole length, said first catalyst is included in platinum group metal on the carrier mass as the catalyst activity component.Filter is characterised in that the carrier mass that is used for the platinum group metal is selected from the oxide of aluminium oxide, silica, titanium dioxide, zirconia, cerium oxide and its mixture or its mixing, and first catalyst also comprises the storage that at least a zeolite is used for hydrocarbon.In addition, particulate filter begins on partial-length, to be coated with second catalyst that does not comprise zeolite from entrance side.
The zeolite that is used for first catalyst preferably has modulus (the Modul) (SiO greater than 10 2With Al 2O 3Mol ratio), so that it is fully stable for the acidic components of waste gas and the highest EGT.The zeolite that is fit to is like modenite, Silicalit, y-type zeolite, ZSM-5 zeolite and β zeolite or its mixture, and the silica that said zeolite has and the mol ratio of aluminium oxide are between 10 and 400.Except zeolite, also can use other material, like activated carbon.
In the work mutually of the engine with low EGT (being lower than about 200 ℃), zeolite is present in the hydrocarbon in the waste gas.This is very important, because under these low EGTs, hydrocarbon can not oxidation on activity of such catalysts noble metal site.In the Diesel engine of passenger vehicle, this work takes place with zero load in cold start-up mutually mutually, and takes place in the urban transportation in modern times.Different with it is, be higher than under about 200 ℃ temperature in temperature, and be main with the desorption of hydrocarbon.Yet under these higher catalyst temperatures, the hydrocarbon that from storage component, discharges can be converted to carbon dioxide and water in the activity of such catalysts site.
In order to increase catalytic activity, can use platinum group metal (platinum, palladium, rhodium, iridium) or transition metal (like iron, copper, cerium) in addition with the zeolite catalysis activation.For the activation of using the platinum group metal, can use the for example aqueous solution dipping zeolite of solubility precursor compound.Behind dipping, with Zeolite dehydration, calcining and undergauge (reduziert) randomly.Based on the gross weight of zeolite and platinum group metal, zeolite is attend the noble metal of institute's load preferably between 0.1 to 10 weight %.
In the situation of using the zeolite that exchanges with transition metal (iron, copper and cerium), through ion-exchange containing transition metal in ammonium or na-pretreated zeolite.Ion-exchange can be carried out in solution or the exchange of so-called solid ionic.Based on gross weight, the transition metal of load is preferably about 1 to 15 weight %.
First catalyst comprises at least a or multiple platinum group metal, the combination of preferred platinum and palladium, wherein the weight ratio of platinum and palladium be 1: 10 to 20: 1, be preferably 1: 1 to 10: 1, particularly 2: 1.The carrier mass that is fit to that is used for the platinum group metal is the oxide of aluminium oxide, silica, titanium dioxide, zirconium dioxide, cerium oxide and its mixture or its mixing.Can make carrier mass thermally-stabilised through rare earth doped oxide, alkaline earth oxide or silica.For example, in the situation of aluminium oxide, doping barium monoxide, lanthana or silica can be paramount to 1100 ℃ from about 950 ℃ of raisings to the conversion temperature of Alpha-alumina with gama-alumina.In oxide and based on the gross weight of stable aluminium oxide, the concentration of doped chemical is generally 1 to 40 weight %.In using the situation of cerium oxide, preferably use the oxide of the mixing of cerium/zirconium, because they have the heat endurance that is higher than the pure zirconia cerium usually as carrier mass.Can come the further stability of the oxide of the mixing of raising cerium/zirconium through doping praseodymium oxide or neodymia.In addition, with regard to the dynamics of maximum oxygen storage capacity and oxygen storage and release, the oxide of the mixing of cerium/zirconium also has good oxygen storage properties.
Particulate filter is coated with second catalyst on the partial-length that its entrance side begins.With regard to catalyst activity noble metal and used carrier mass, said second catalyst can be identical or different with first catalyst.For other coating, the preferred catalyst that has same composition with first catalyst that uses.Yet second catalyst does not comprise any zeolite.The length of second catalyst can be filter base (Filtersubstrates) total length 5 to 80%, preferred 10 to 50%.
Use the gradient concentration that second catalyst causes the catalyst activity component from the filter inlet side.More catalyst activity component is present in the front portion of filter.This have be arranged near the situation of the diesel particulate filter of the integrated oxidization catalyst at engine place in advantageous particularly.This is because the carborundum filter base of usually using has big thermal mass (thermischen Masse) and strong axial-temperature gradient in the test loop of standard code such as NEDC (NewEuropean Driving Cycle).For example, particularly using long relatively diesel particulate filter (in＞150mm) the situation,, in whole test loop, can not reach the required temperature of carbon monoxide and hydrocarbon conversion usually at the rear portion of the filter that is arranged on downstream.Therefore, in the situation of the filter that evenly applies, a part of noble metal only promotes on not half or even does not promote the conversion of carbon monoxide and hydrocarbon fully.Therefore; Particularly in the situation of the filter that is provided with near engine; It is advantageously that noble metal is distributed in the length of particulate filter in gradient, so that the zone with higher noble metal load is at entrance side and have zone than the low noble metal load at outlet side.Yet; Precious metal concentration in the filter outlet side should be not less than minimum about 0.1g/l; This is because otherwise in the situation of activated filter film device regeneration, can have the risk of so-called secondary emission
Figure G2007800347195D00051
, i.e. the breakthrough of carbon monoxide and hydrocarbon (Durchbr ü chen).
In the coating of diesel particulate filter, should be specifically noted that minimum increase through the back pressure of coating.Have been found that when catalyst material is deposited in the porous wall of filter base basically the increase of the back pressure through coating can keep very low.For this purpose, can use several different methods:
■ adds with the form of the solid powder substance that in the aqueous solution, suspends, in this situation the average grain diameter of powdered rubber must be significantly less than the average pore size of filter base;
■ adds with the form of colloidal sol;
■ adds with the form of the precursor solution of carrier mass in the back, and it only can change into its final form through final calcining.
Form with solid powder substance adds catalytic activity and the heat endurance that catalyst material obviously is superior to other two kinds of painting methods.Different with it is; With regard to the back pressure behavior of the particulate filter that applies; So that the form of the precursor solution of carrier mass adds and to have tangible advantage in the back, therefore particularly in the situation of using harsh (low porosity, harmonic(-)mean aperture) substrate, it is the painting method that is fit to.
In the situation of using solid powder substance,, it is for example being ground and suspension in the water from the purpose that the particle diameter that homogenizes and obtain to limit distributes.Grind so that in the suspension maximum particle diameter for less than 10 μ m.Normal conditions are d 50Diameter is less than 2 μ m.Have only this little particle diameter could make catalyst almost only be deposited in the hole of substrate.Carrier mass used in the suspension is added into suspension before just by the platinum family element activation at it usually.Yet, also can be only in the suspension of carrier mass, add the precursor compound of dissolving of the platinum group metal of catalyst activity.In addition, after carrier mass is applied to filter base, also can be subsequently with the solubility precursor dipping of filter with the platinum group metal.
Have been found that for catalyst material and zeolite and should preferably obtain particle diameter respectively through grinding.Catalyst material has different hardness with zeolite.Have only through grinding respectively for two kinds of materials and just can guarantee to obtain suitable particle diameter and distribute.Therefore, for the coating of filter, at first prepare two kinds of independent suspension.First suspension comprises the carrier mass with noble metal (like platinum, palladium) activation.Second suspension comprises zeolite.Thereby in the step in front preferably through the dipping or carry out ion-exchange with noble metal zeolite mixed.Yet, also can under the help of the precursor compound that is fit to, in zeolite suspension, add noble metal.In the situation of two kinds of suspension, obtain average grain diameter d respectively through grinding subsequently less than 2 μ m 50d 90Value should be not more than 5-6 μ m.Before being about to carry out practical, coated technology, two kinds of suspension are mixed and homogeneous.
First and second catalyst can comprise zeolite.Yet, have been found that when zeolite is evenly distributed in the whole length of filter, be favourable to diesel particulate filter near the engine setting.In this case, have only first catalyst to comprise zeolite.Therefore second catalyst only is used for increasing the concentration of the catalyst activity noble metal of particulate filter front portion.In the situation of this kind setting, particularly under transition state (transienten Bedingungen) as in NEDC, can preferably utilize the axial temperature in the filter to distribute, it is a highly significant in the situation of the filter base that comprises carborundum.
The distribution influence of zeolite between first and second catalyst is through the development of the exhaust back-pressure of the filter of coating.When only in second catalyst, adding zeolite, back pressure is significantly higher than the back pressure when in the whole length of filter, using first catalyst to apply zeolite equably.Different with it is, and the zeolite facies ratio only is set in first catalyst, in first and second catalyst, uses the whole load capacity of zeolite of equivalent, in the back pressure behavior, does not demonstrate significant difference.
In theory, the storage capacity for hydrocarbon increases along with the increase of amount of zeolite.Yet the maximum available quantity of zeolite depends on the porosity and the average pore size of filter device therefor substrate significantly.Usually the loading range of zeolite is the about 50g/l of 5g/l (filter volume) to the situation of high relatively porosity (＞50%) substrate in the situation of low porosity substrate (＜50%).Be preferably 0.1 to 10 in particulate filter mesolite of the present invention and the ratio that is doped with the carrier mass of noble metal.
Known filter base is applicable to diesel particulate filter.The preferred so-called wall-flow filter that comprises carborundum, cordierite, aluminium titanates or mullite that uses.For catalyst material and zeolite optimization ground is got in the hole of filter base, the material of filter should have porosity between 40% and 80% and the open-celled structure (offenporigeStruktur) of average pore size between 9 and 30 μ m.
Embodiment
With reference now to following examples and accompanying drawing, the present invention will be described.Prepare the diesel particulate filter that some have different coating, and in block testing stand and test vehicle, test their clean-up performances in the test loop of NEDC Europe.(atmosphere comprises 10%H at fresh state and hydrothermal aging 2O, 10% O 2, surplus N 2, in 750 ℃ batch-type furnace 16 hours) the post analysis filter.
The substrate of under various situation, using is the filter that comprises carborundum, and the cell density (Zelldichte) of said carborundum is 46.5cm -1(300cpsi) and passage wall thickness be 0.3mm (12mil).The porosity of filter device therefor material is 60%; Average pore size is 20 μ m.The length of filter body is 152.4mm.
Back pressure is measured:
In order to analyze the influence of particulate filter load zeolite, in back pressure apparatus 150 and 300m 3Having measured load under the flow velocity of/h has the back pressure of three kinds of particulate filters of different carriers oxide and zeolite.
Not load of filter 1.Filter 2 has the coating that comprises aluminum oxide suspension, and it has the load concentration of about 30g/l after dry and calcining.Filter 3 is coated with the zeolite mixture (mixed proportion 1: 1) of aluminium oxide and y-type zeolite and β zeolite.According to the present invention, grind respectively aluminium oxide and zeolite up to the average grain diameter of aluminium oxide and zeolite less than 2 μ m.Filter 3 loads have the aluminium oxide of 30g/l and the zeolite mixture of 10g/l.
Mensuration on the back pressure apparatus shows, compares with the filter 1 of uncoated, makes back pressure increase about 15% to 20% with pure alumina suspension filter application 2.Different with it is, compares with the substrate of uncoated, and the zeolite that in the situation of filter 3, only adds 10g/l can make back pressure increase about 50%.
Comparing embodiment (filter C):
At first in the whole length of filter, use and be supported on the Pt/Pd catalyst filter application substrate equably on the stable gama-alumina.Abrasive coated suspension is less than 2 μ m up to average grain diameter.Therefore, coating step almost deposits catalyst material in the hole that gets into filter base fully.The Pt/Pd ratio of said first catalyst layer is that 2: 1 and noble metal load are 2.12g/l (60g/ft 3).In second coating step, in filter length half the, use bullion content and be similarly 2.12g/l (60g/ft 3) and second catalyst layer with identical Pt/Pd ratio.Therefore relatively total noble metal load of filter C gained is about 90g/ft 3, or 3.18g/l.Second catalyst layer also mainly enters into the hole of filter base.
Embodiment 1 (filter F 1):
With catalyst-coated second filter base of the present invention.At first in the whole length of filter, use 60g/ft 3Noble metal load filter application equably.Yet different with comparing embodiment is, coating of the present invention also comprises the zeolite mixture (mixed proportion 1: 1) that comprises y-type zeolite and β zeolite except comprising with the stable gama-alumina of the Pt/Pd of 2: 1 ratios.Be added into apply suspension before, through the dipping method little P t (0.5 weight %) that in two kinds of zeolites, all mixes.The ratio of gama-alumina and zeolite mixture is about 1: 1.After this, in next step coating step, use identical coating suspension, apply the noble metal of extra 2.12g/l at the entrance side (in the length at 76.2mm) of filter.Therefore, the total concentration of precious metals pt on the filter F 1 and Pd is 3.18g/l (90g/ft 3), the Pt/Pd ratio is 2: 1.
In the passenger vehicle of the EURO IV of Diesel engine standard, after fresh state and damp and hot stove are aging, carry out the test of the catalytic activity of two kinds of filters with the 103kW 2.0l that has the unit fuel injector spraying system.Filter near the engine setting, and is not being had to analyze under the condition of upper reaches diesel oxidation catalyst in NEDC (New European Driving Cycle) test loop.Comprise that the untreated emission result of vehicle is summarised in the table 1.
Discharging among the NEDC clearly illustrates uses zeolite to reduce the HC discharging after fresh state and strong heat ageing (16 hours, 790 ℃) significantly as the HC storage component in filter F 1.It should be noted that the discharging for CO also is like this.After aging, the minimizing of observing the CO discharging is greater than 30%.
Embodiment 2 (filter F 2 and F3):
Similar with embodiment 1 (filter F 1), use the noble metal load of 3.18g/l to apply other two kinds of filter base.Different with filter F 1, in filter F 2, in the whole length of filter, only use the zeolite of 20g/l amount at first catalyst layer.In filter F 3, only use zeolite at second catalyst layer.For example in embodiment 1, used zeolite is the mixture (mixed proportion 1: 1) of y-type zeolite and β zeolite.Two kinds of used zeolites have been doped with the Pt of 0.5 weight % respectively.
In the passenger vehicle of the EURO IV of Diesel engine standard, after fresh state and damp and hot stove are aging, carry out equally the test of the catalytic activity of filter F 2 and F3 with the 103kW 2.0l that has the unit fuel injector spraying system.The result is summarised in the table 1 equally.
Particularly behind 790 ℃ of following hydrothermal agings, for hydrocarbon that discharges among the NEDC and CO discharging, find that filter F 2 and F3 also have improved discharge performance.Discovery is used the HC storage component in the whole length of filter be favourable.With only in first catalyst, use the zeolite facies ratio, the amount of zeolite is divided in first and second catalyst do not demonstrate advantage.With regard to the discharging of hydrocarbon among the NEDC and carbon monoxide, only in second catalyst, use zeolite not fully up to expectations.Compare with F1, the HC discharging increases about 60%; The CO discharging increases about 18%.Even now is compared with the filter V of comparing embodiment, in " high capacity " of filter inlet district, uses zeolite to make that still the discharging of pollutant significantly reduces among the NEDC.
Table 1:The untreated discharging of CO and HC and bag discharging (Beutelemissionen) in NEDC (diesel-powered bus 103kW, 2.0l Euro IV standard)
Filter State CO discharges [g/km] HC discharges [g/km]
Untreated discharging - 0.96 0.23
V Fresh 0.033 0.039
V Aging 0.230 0.056
F1 Fresh 0.027 0.012
F1 Aging 0.157 0.029
F2 Fresh 0.044 0.013
F3 Fresh 0.048 0.021
F2 Aging 0.143 0.028
F3 Aging 0.185 0.047
Embodiment 3 (filter F 4, F5, F6, F7):
In other test event, use the particulate filter of four kinds of catalyst-coated of zeolite coating of different amounts.Use with filter F 1 similar method and prepare four kinds of filter F 4 to F7.At first in the whole length of filter, use 2.12g/l (to be equivalent to 60g/ft 3) noble metal load filter application equably.In second coating step, in the length areas of 76.2mm, use the noble-metal coated filter of extra 2.12g/l, so that obtain 90g/ft 3(Pt/Pd=2: total noble metal load 1).Though it is constant that the amount of support oxide (stable gama-alumina) keeps; But use the zeolite (10 to 40g/l) of different amounts to apply four kinds of filters, the zeolite mixture that comprise 50%Y type zeolite and 50% β zeolite identical with the zeolite mixture that is used for filter F 1 has been used to first and second catalyst.Pt concentration is 0.5 weight % on the zeolite.Table 2 has shown the composition of four kinds of filter F 4-F7 of the present invention.
For the HC storage capacity of testing filter of the present invention and the functional relation of zeolite content, store test having on the four cylinder Diesel engines (2.2l, 100kW) of common-rail injection system.The constant engine operating point that is about 110 ℃ in the filter inlet temperature stores test.By FID analyzer (AMA2000, Pierburg) the HC discharging of record catalyst upstream and downstream.Storing test respectively reaches steady state value and continues about 10 minutes up to the HC in catalyst downstream concentration.The amount of the HC that stores from the HC concentration determination of catalyst upstream and downstream:
Result displayed has clearly illustrated that owing to use zeolite can increase the amount of the HC of storage significantly in the table 2.Even the zeolite that uses 10g/l just can make the amount that stores the hydrocarbon that stores in the test increase by 2.5 times.Through the content of the single catalyst mesolite of further increase, the HC storage capacity continues to increase.Have only when zeolite content is higher than 25g/l and just saturated behavior can take place.
Table 2:Be used for the bullion content of filter F 4 to F7 and the amount of HC zeolite-loaded and that HC storage test period stores on block testing stand
Filter NM content [g/l] Zeolite-loaded [g/l] The quality [g] of the HC that stores
V 90 Do not have 1.29
F4 90 10 2.49
F5 90 17 3.62
F6 90 23 4.77
F7 90 40 5.74
Store through HC and to become to assign to store the absorption that hydrocarbon has reduced hydrocarbon on the catalyst activity oxidation site.This also can advantageously influence the conversion of carbon monoxide.
Basically suppressed its side effect in the hole of zeolite entering filter base to filter backpressure.

Claims (12)

1. be used to handle the particulate filter of diesel engine exhaust; It comprises entrance side and outlet side and the shaft length that is used for waste gas; Said particulate filter is coated with first catalyst; Said first catalyst is included in platinum group metal on the carrier mass as the catalyst activity component; The carrier mass that it is characterized in that being used for the platinum group metal is selected from the oxide of aluminium oxide, silica, titanium dioxide, zirconia, cerium oxide and its mixture or its mixing, and said first catalyst comprises that also at least a zeolite is used for the storage of hydrocarbon, and said particulate filter begins on partial-length, to be coated with second catalyst that does not comprise zeolite from entrance side.
2. particulate filter as claimed in claim 1 is characterized in that said zeolite is selected from modenite, Silicalit, y-type zeolite, ZSM-5 zeolite and β zeolite or its mixture, and the silica of said zeolite and the mol ratio of aluminium oxide are between 10 and 400.
3. particulate filter as claimed in claim 2 is characterized in that said zeolite and transition metal ions exchange.
4. particulate filter as claimed in claim 3 is characterized in that the said transition metal that exists is iron, copper or cerium or its mixture.
5. particulate filter as claimed in claim 2 is characterized in that said zeolite exists with H or Na type, and equally by at least a platinum group metal catalyzed activation, based on the gross weight of zeolite, the concentration of platinum group metal is between 0.1 weight % and 10 weight %.
6. particulate filter as claimed in claim 1 is characterized in that two kinds of catalyst all comprise platinum and the palladium of weight ratio between 1: 10 and 20: 1 as the platinum group metal.
7. particulate filter as claimed in claim 1 is characterized in that comprising in said first catalyst that the weight ratio of zeolite of support oxide and the doping of platinum group is 0.1 to 10.
8. like one of aforementioned claim described particulate filter, it is characterized in that said catalyst gets in the hole of particulate filter basically.
9. particulate filter as claimed in claim 1; It is characterized in that said particulate filter comprises wall-flow filter, said wall-flow filter comprises ceramic masses and its wall and has porosity between 40% and 80% and the open-celled structure of average pore size between 9 μ m and 30 μ m.
10. the method for preparing the described particulate filter of one of aforementioned claim is characterized in that on said first catalyst and second catalyst administered to the said particulate filter with the suspension coating.
11. method as claimed in claim 10; It is characterized in that in various situation; At first prepare two kinds of suspension and be used for each single catalyst coat; A kind of suspension comprises with the carrier mass of platinum group metal activation and second kind of suspension and comprises zeolite, and two kinds of suspension all are ground to average grain diameter less than 2 μ m, and before being about to filter application, both is mixed and homogenising.
12. be used for reducing the application of level of carbon monoxide, hydrocarbon and the soot particulates of diesel engine exhaust like the described particulate filter of one of claim 1 to 9.
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